Method for producing double metal cyanide catalysts

ABSTRACT

The present invention relates to a process for preparing a double metal cyanide catalyst (DMC) comprising the reaction of an aqueous solution of a cyanide-free metal salt, an aqueous solution of a metal cyanide salt, an organic complex ligand and a complex-forming component, to form a dispersion, wherein the reaction is effected using a mixing nozzle and wherein the process temperature of the dispersion during the reaction is between 26° C. and 49° C. The subject matter of the invention further encompasses double metal cyanide catalysts (DMC) obtainable in accordance with the process according to the invention and also the use of the DMC catalysts for the preparation of polyoxyalkylene polyols.

The present invention relates to an improved process for preparing double metal cyanide (DMC) catalysts for the preparation of polyoxyalkylene polyols, preferably polyether polyols and/or polyether carbonate polyols. Further provided are DMC catalysts which are obtainable via this process and also the use of the catalysts according to the invention for the preparation of polyoxyalkylene polyols.

DMC catalysts are known in principle from the prior art (see, for example, U.S. Pat. Nos. 3,404,109, 3,829,505, 3,941,849, and 5,158,922). DMC catalysts, which are described, for example, in U.S. Pat. No. 5,470,813, EP-A 700 949, EP-A 743 093, EP-A 761 708, WO 97/40086, WO 98/16310 and WO 00/47649, have a very high activity in the homopolymerization of epoxides and enable the preparation of polyether polyols at very low catalyst concentrations (25 ppm or lower), such that removal of the catalyst from the finished product is generally no longer required. A typical example is that of the highly active DMC catalysts which are described in EP-A 700 949 and contain not only a double metal cyanide compound (e.g. zinc hexacyanocobaltate(III)) and an organic complex ligand (e.g. tert-butanol) but also a polyether having a number-average molecular weight greater than 500 g/mol.

WO 01/39883 A1 discloses a process for preparing double metal cyanide (DMC) catalysts for the preparation of polyether polyols by polyaddition of alkylene oxides onto starter compounds having active hydrogen atoms, the DMC catalyst dispersion being prepared in this process using a mixing nozzle, preferably a jet disperser. The DMC catalysts thus prepared have increased activity in the preparation of polyether polyols, reduced particle size and a narrower particle size distribution.

WO 01/80994 A1 likewise discloses a process for preparing double metal cyanide (DMC) catalysts, in which aqueous solutions of a metal salt and of a metal cyanide salt are first reacted in the presence of an organic complex ligand and optionally one or more further complex-forming components to form a DMC catalyst dispersion, this dispersion is then filtered, the filtercake is subsequently washed with one or more aqueous or nonaqueous solutions of the organic complex ligand and optionally one or more further complex-forming components by filtercake washing, and the washed filtercake is finally dried after an optional pressing out or mechanical moisture removal. The process disclosed shortens the time for catalyst preparation, the resulting catalysts possessing comparable activities in the preparation of polyether polyols in comparison to reference catalysts.

WO 2011/144523 A1 discloses polyether carbonate polyols formed from one or more H-functional starter substances, one or more alkylene oxides and carbon dioxide in the presence of at least one double metal cyanide catalyst, wherein the cyanide-free metal salt, metal cyanide salt or both mentioned salts used for the preparation of the double metal cyanide catalyst is/are reacted in the presence of defined amounts of alkaline compounds. These DMC catalysts lead to an improved selectivity in favor of the formation of linear polyether carbonate polyols.

EP 700 949 A2 describes a DMC catalyst, containing DMC compound, an organic complex ligand and 5%-80% by weight of a polyether having a number-average molecular weight of >500 g/mol, the preparation of the DMC catalyst dispersion being effected at room temperature. The catalysts used generally possess an activity in the preparation of polyether polyols.

The relevance of the temperature setting/control in the preparation of the DMC dispersion and the influence thereof on the DMC catalyst activity for the formation of polyoxyalkylene polyols is not disclosed in the prior art.

The object of the present application was to provide an improved process for preparing double metal cyanide (DMC) catalysts having further increased catalytic activity in the preparation of polyoxyalkylene polyols, preferably polyether polyols and/or polyether carbonate polyols, this improved activity resulting in a reduced product viscosity for example in the catalyst test according to the “8K diol stressed tests” described for example in WO 98/16310 A1. The aim was thus to provide catalytically more active DMC catalysts which lead to polyoxyalkylene polyols, preferably polyether polyols and/or polyether carbonate polyols, having a reduced viscosity, which facilitates the further processability of the polyoxyalkylene polyols in the subsequent polyurethanization reaction. The increased catalyst activity moreover enables a reduction in the amount of catalyst used, which improves the economic viability of the process.

At the same time, the preparation process of the DMC catalyst dispersion should be effected with a comparably simple apparatus setup, a low energy expenditure for the shearing, good temperature control, and also a likewise good scalability compared to known industrial processes, in order to enable a simple implementation in existing DMC catalyst preparation processes, for example in loop reaction.

Surprisingly, it has now been found that a process for preparing a double metal cyanide catalyst (DMC) comprising

-   -   i) in a first step, the reaction of an aqueous solution of a         cyanide-free metal salt, an aqueous solution of a metal cyanide         salt, an organic complex ligand and a complex-forming component,         to form a dispersion;         wherein the reaction is effected using a mixing nozzle;         and wherein the process temperature of the dispersion during the         reaction is between 26° C. and 49° C., solves the abovementioned         object.

Cyanide Free Metal Salt

Cyanide-free metal salts suitable for preparation of the double metal cyanide compounds preferably have the general formula (I)

M(X)_(n)  (I)

where M is selected from the metal cations Zn²⁺, Fe²⁺, Ni²⁺, Mn²⁺, Co²⁺, Sr²⁺, Sn²⁺, Pb²⁺ and Cu²⁺; M is preferably Zn²⁺, Fe²⁺, Co²⁺ or Ni²⁺, X are one or more (i.e. different) anions, preferably an anion selected from the group of halides (i.e. fluoride, chloride, bromide, iodide), hydroxide, sulfate, carbonate, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate, oxalate and nitrate; n is 1 when X=sulfate, carbonate or oxalate and n is 2 when X=halide, hydroxide, cyanate, thiocyanate, isocyanate, isothiocyanate or nitrate, or suitable cyanide-free metal salts have the general formula (II)

M_(r)(X)₃  (II)

where M is selected from the metal cations Fe³⁺, Al³⁺ and Cr³⁺, X are one or more (i.e. different) anions, preferably an anion selected from the group of halides (i.e. fluoride, chloride, bromide, iodide), hydroxide, sulfate, carbonate, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate, oxalate and nitrate; r is 2 when X=sulfate, carbonate or oxalate and r is 1 when X=halide, hydroxide, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate or nitrate, or suitable cyanide-free metal salts have the general formula (III),

M(X)_(s)  (III)

where M is selected from the metal cations Mo⁴⁺, V⁴⁺ and W⁴⁺, X are one or more (i.e. different) anions, preferably an anion selected from the group of halides (i.e. fluoride, chloride, bromide, iodide), hydroxide, sulfate, carbonate, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate, oxalate and nitrate; s is 2 when X=sulfate, carbonate or oxalate and s is 4 when X=halide, hydroxide, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate or nitrate, or suitable cyanide-free metal salts have the general formula (IV),

M(X)_(t)  (IV)

where M is selected from the metal cations Mo⁶⁺ and W⁶⁺, X are one or more (i.e. different) anions, preferably an anion selected from the group of halides (i.e. fluoride, chloride, bromide, iodide), hydroxide, sulfate, carbonate, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate, oxalate and nitrate; t is 3 when X=sulfate, carbonate or oxalate and t is 6 when X=halide, hydroxide, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate or nitrate,

In a preferred embodiment of the process according to the invention, the cyanide-free metal salt of the aqueous solution of a cyanide-free metal salt is one or more compound(s) and is selected from the group consisting of zinc chloride, zinc bromide, zinc iodide, zinc acetate, zinc acetylacetonate, zinc benzoate, zinc nitrate, iron(II) sulfate, iron(II) bromide, iron(II) chloride, cobalt(II) chloride, cobalt(II) thiocyanate, nickel(II) chloride and nickel(II) nitrate.

Metal Cyanide Salt

Metal cyanide salts suitable for preparation of the double metal cyanide compounds preferably have the general formula (V)

(Y)_(a)M′(CN)_(b)(A)_(c)  (V)

where M′ is selected from one or more metal cations from the group consisting of Fe(II), Fe(III), Co(II), Co(III), Cr(II), Cr(III), Mn(II), Mn(III), Ir(III), Ni(II), Rh(III), Ru(II), V(IV) and V(V); M′ is preferably one or more metal cations from the group consisting of Co(II), Co(III), Fe(II), Fe(III), Cr(III), Ir(III) and Ni(II), Y is selected from one or more metal cations from the group consisting of alkali metal (i.e. Li⁺, Na⁺, K⁺, Rb⁺, Cs⁺) and alkaline earth metal (i.e. Be²⁺, Ca²⁺, Mg²⁺, Sr²⁺, Ba²⁺), A is selected from one or more anions from the group consisting of halides (i.e. fluoride, chloride, bromide, iodide), hydroxide, sulfate, carbonate, cyanate, thiocyanate, isocyanate, isothiocyanate, carboxylate, oxalate or nitrate and a, b and c are integers, the values for a, b and c being selected such as to ensure the electronic neutrality of the metal cyanide salt; a is preferably 1, 2, 3 or 4; b is preferably 4, 5 or 6; c preferably has the value 0.

In a preferred embodiment of the process according to the invention, the metal cyanide salt of the aqueous solution of a metal cyanide salt is one or more compound(s) and is selected from the group consisting of potassium hexacyanocobaltate(III), potassium hexacyanoferrate(II), potassium hexacyanoferrate(III), calcium hexacyanocobaltate(III) and lithium hexacyanocobaltate(III).

Preferred double metal cyanide compounds present in the DMC catalysts according to the invention are compounds of the general formula (VI)

M_(x)[M′_(x),(CN)_(y)]_(z)  (VI),

where M is as defined in formula (I) to (IV) and M′ is as defined in formula (V), and x, x′, y and z are integers and are selected such as to ensure the electronic neutrality of the double metal cyanide compound.

Preferably,

x=3, x′=1, y=6 and z=2,

M=Zn(II), Fe(II), Co(II) or Ni(II) and

M′=Co(III), Fe(III), Cr(III) or Ir(III).

In a preferred embodiment of the process according to the invention, the double metal cyanide compound is one or more compound(s) and is selected from the group consisting of zinc hexacyanocobaltate(III), zinc hexacyanoiridate(III), zinc hexacyanoferrate(III) and cobalt(II) hexacyanocobaltate(III). Particular preference is given to using zinc hexacyanocobaltate(III).

Organic Complex Ligand

The organic complex ligands added in the preparation of the DMC catalysts are disclosed, for example, in U.S. Pat. No. 5,158,922 (see especially column 6, lines 9 to 65), U.S. Pat. Nos. 3,404,109, 3,829,505, 3,941,849, EP-A 700 949, EP-A 761 708, JP 4 145 123, U.S. Pat. No. 5,470,813, EP-A 743 093 and WO-A 97/40086). For example, organic complex ligands used are water-soluble organic compounds having heteroatoms, such as oxygen, nitrogen, phosphorus or sulfur, which can form complexes with the double metal cyanide compound. Preferred organic complex ligands are alcohols, aldehydes, ketones, ethers, esters, amides, ureas, nitriles, sulfides and mixtures thereof. Particularly preferred organic complex ligands are aliphatic ethers (such as dimethoxyethane), water-soluble aliphatic alcohols (such as ethanol, isopropanol, n-butanol, isobutanol, sec-butanol, tert-butanol, 2-methyl-3-buten-2-ol and 2-methyl-3-butyn-2-ol), compounds containing both aliphatic or cycloaliphatic ether groups and aliphatic hydroxyl groups (for example ethylene glycol mono-tert-butyl ether, diethylene glycol mono-tert-butyl ether, tripropylene glycol monomethyl ether and 3-methyl-3-oxetanemethanol). The most preferred organic complex ligands are selected from one or more compounds from the group consisting of dimethoxyethane, tert-butanol, 2-methyl-3-buten-2-ol, 2-methyl-3-butyn-2-ol, ethylene glycol mono-tert-butyl ether and 3-methyl-3-oxetanemethanol.

In a preferred embodiment of the process according to the invention, the organic complex ligand is one or more compound(s) and is selected from the group consisting of dimethoxyethane, tert-butanol, 2-methyl-3-buten-2-ol, 2-methyl-3-butyn-2-ol, ethylene glycol mono-tert-butyl ether and 3-methyl-3-oxetanemethanol.

Complex-Forming Component

Used in the process according to the invention for preparing the DMC catalysts are one or more complex-forming component(s) from the compound classes of the polyethers, polyesters, polycarbonates, polyalkylene glycol sorbitan esters, polyalkylene glycol glycidyl ethers, polyacrylamide, poly(acrylamide-co-acrylic acid), polyacrylic acid, poly(acrylic acid-co-maleic acid), polyacrylonitrile, polyalkyl acrylates, polyalkyl methacrylates, polyvinyl methyl ether, polyvinyl ethyl ether, polyvinyl acetate, polyvinyl alcohol, poly-N-vinylpyrrolidone, poly(N-vinylpyrrolidone-co-acrylic acid), polyvinyl methyl ketone, poly(4-vinylphenol), poly(acrylic acid-co-styrene), oxazoline polymers, polyalkyleneimines, maleic acid and maleic anhydride copolymers, hydroxyethylcellulose and polyacetals, or of the glycidyl ethers, glycosides, carboxylic esters of polyhydric alcohols, esters or amides, cyclodextrins or phosphorus compounds.

In the process according to the invention for preparing the DMC catalysts, as complex-forming component, polyethers are preferably used.

In a preferred embodiment, the polyether has a number-average molecular weight of ≥500 g/mol, the number-average molecular weight being calculated from the OH number determined.

OH numbers are determined according to the method of DIN 53240.

Suitable polyethers include those which are prepared by means of the ring-opening polymerization of cyclic ethers, these cyclic ethers for example also comprising oxetane polymers and also tetrahydrofuran polymers. Any catalysis is possible for this. The polyethers have suitable end groups here, such as for example hydroxyl, amine, ester or ether end groups.

In a particularly preferred embodiment, the polyether has an average hydroxyl functionality of from 2 to 8 and a number-average molecular weight in the range from 500 g/mol to 10 000 g/mol, preferably of from 700 g/mol to 5000 g/mol, the number-average molecular weight being calculated from the OH number determined.

In a particularly preferred embodiment, the polyethers are polyether polyols, the polyether polyols being obtained by reaction of alkylene oxides and H-functional starter compounds in the presence of acidic, basic and/or organometallic catalysts. These organometallic catalysts are for example double metal cyanide (DMC) catalysts.

Suitable polyether polyols are poly(oxypropylene) polyols, poly(oxypropyleneoxyethylene) polyols, polytetramethylene ether glycols and block copolymers containing poly(oxy)ethylene, poly(oxy)propylene and/or poly(oxy)butylene blocks, such as for example poly(oxy)ethylene-poly(oxy)propylene block copolymers having terminal poly(oxy)ethylene blocks.

In a preferred embodiment, the polyether polyol is a poly(oxypropylene) polyol having a number-average molecular weight of ≥500 g/mol, the number-average molecular weight being calculated from the OH number determined.

In a particularly preferred embodiment, the polyether polyol is a poly(oxypropylene) polyol, preferably a poly(oxypropylene) diol and/or a poly(oxypropylene) triol having a number-average molecular weight of 700 g/mol to 4000 g/mol, the number-average molecular weight being calculated from the OH number determined.

In an alternative embodiment, the polyethers have an average hydroxyl functionality of from 2 to 8 and a number-average molecular weight in the range from 150 g/mol to less than 500 g/mol, preferably of from 200 g/mol to 400 g/mol, the number-average molecular weight being calculated from the OH number determined.

In a preferred alternative embodiment, the alternative polyethers are polyether polyols, these alternative polyether polyols having an average hydroxyl functionality of from 2 to 8 and a number-average molecular weight in the range from 150 g/mol to less than 500 g/mol, preferably an average hydroxyl functionality of from 2 to 8 and a number-average molecular weight in the range from 200 g/mol to 400 g/mol, the number-average molecular weight being calculated from the OH number determined. These alternative polyether polyols are likewise obtained by reaction of alkylene oxides and H-functional starter compounds in the presence of acidic, basic and/or organometallic catalysts. These organometallic catalysts are for example double metal cyanide (DMC) catalysts.

Suitable alternative polyether polyols are poly(oxypropylene) polyols, poly(oxypropyleneoxyethylene) polyols, polytetramethylene ether glycols and block copolymers containing poly(oxy)ethylene, poly(oxy)propylene and/or poly(oxy)butylene blocks, such as for example poly(oxy)ethylene-poly(oxy)propylene block copolymers having terminal poly(oxy)ethylene blocks. Tripropylene glycol, triethylene glycol, tetrapropylene glycol, tetraethylene glycol, dipropylene glycol monomethyl ether, tripropylene glycol monomethyl ether, and monoalkyl and dialkyl ethers of glycols and poly(alkylene glycol)s are furthermore also suitable.

In a particularly preferred alternative embodiment, the alternative polyether polyol is a polypropylene glycol and/or a polyethylene glycol having a number-average molecular weight in the range from 150 g/mol to less than 500 g/mol, the number-average molecular weight being calculated from the OH number determined.

Mixing Nozzle

The DMC catalyst dispersion is prepared using a mixing nozzle (for example a smooth jet nozzle, Levos nozzle, Bosch nozzle and the like), preferably a jet disperser, as is described in the German patent application WO 01/39883 A1.

The basic structure and mode of operation of suitable mixing nozzles will be described hereinbelow. FIG. 1 shows the schematic structure of a simple smooth jet nozzle. The reactant stream 1 is first accelerated in the nozzle 3 and sprayed at a high flow speed into the slow-flowing reactant stream 2. In the process, reactant stream 2 is accelerated and reactant stream 1 is decelerated. Part of the kinetic energy of reactant jet 1 is converted into heat in this process and is thus no longer available for the mixing operation. The two reactant streams are subsequently mixed via the turbulent decay of the resulting jet into vortices of different sizes (vortex cascade). Compared to a stirred tank, concentration differences can be reduced much more rapidly in this way, as much greater and more homogeneous power densities can be achieved. The average power density P is calculated here by the following formula:

$P = \frac{\Delta\;{p \cdot \overset{.}{V}}}{V}$

with: Δp: pressure drop in the nozzle

-   -   {dot over (V)}: volume flow rate     -   V: volume of the nozzle bore

The use of such nozzles will be designated hereinbelow as method 1.

In a smooth jet nozzle, a first reactant stream is first accelerated in a nozzle and sprayed at a high flow speed into a slow-flowing second reactant stream. The two reactant streams are subsequently mixed via the turbulent decay of the resulting jet into vortices of different sizes (vortex cascade). Compared to a stirred tank, concentration differences can be reduced much more rapidly in this way, as much greater and more homogeneous power densities can be achieved.

Jet Disperser

Preference is given to using a jet disperser as is illustrated in FIG. 2 or FIG. 3 for the process according to the invention. The jet disperser can be constructed (FIG. 2) such that two nozzles 5 and 6 are arranged in succession. The reactant stream 1 is first greatly accelerated in nozzle 5 by the cross-sectional constriction. The accelerated jet in the process draws in the second component due to the high flow speed. The spacing of the nozzles is preferably selected so that only nucleation, but no crystal growth, occurs in the mixing chamber 4 on account of the short residence time. The decisive factor for the optimal design of the jet disperser is thus the nucleation speed of the solid. A residence time of 0.0001 s to 0.15 s, preferably 0.001 s to 0.1 s, is advantageously set. The crystal growth first takes place in the outlet 3. The diameter of the nozzles 6 should preferably be selected so that the partially mixed reactant streams are accelerated further there. Due to the shear forces additionally arising as a result in the nozzles 6, compared to method 1, the state of homogeneous mixing is achieved in a shorter time because of a more rapid vortex decay. As a result, in contrast to method 1, it is possible even in the case of precipitation reactions with a very high nucleation rate to achieve the state of ideal mixing of the reactants, so that the setting of defined stoichiometric compositions during the precipitation reaction is possible. Nozzle diameters of from 5000 μm to 50 μm, preferably 2000 μm to 200 μm, have proven to be advantageous with pressure drops in the nozzle of 0.1 bar to 1000 bar or power densities in the range from 1*10′ W/m³ to 1*10¹³ W/m³. This mixing operation will be designated hereinbelow as method 2.

Depending on the desired particle size, a further n nozzles (with n=1-5) may be connected downstream so as to obtain a multistage jet disperser. FIG. 3 shows such a multistage jet disperser. Following the nozzle 6, the dispersion is once more guided through the nozzle 7. For the design of the nozzle diameter, the same applies as for nozzle 6.

The additional advantage of further dispersers compared to method 2 consists in that particles which have already formed can be mechanically comminuted by the large shear forces in the nozzles. In this way it is possible to produce particles having diameters of from 10 μm to 0.1 μm. Instead of a plurality of nozzles connected in series, comminution can also be achieved by circulating the dispersion. The use of such nozzles will be identified hereinbelow as method 3.

The energy dissipation in the nozzles and the enthalpy of crystallization can result in heating of the dispersion. Since the temperature can have a substantial influence on the crystal formation process, a heat transfer means may be installed downstream of the mixing element for the isothermal process regime.

A problem-free scale up is for example possible by using a relatively large number of bores, connecting a plurality of mixing elements in parallel or enlarging the free nozzle area. However, the latter is not achieved by increasing the nozzle diameter, as this gives rise to the possibility of the occurrence of a core flow which results in a deterioration in the mixing result. For nozzles having large free nozzle areas, it is therefore preferable to use slits having a corresponding area.

The DMC catalyst dispersion is prepared according to the invention using a mixing nozzle, preferably a jet disperser. Examples of suitable apparatuses are shown in FIGS. 4 and 5. FIG. 4 shows a semi-batchwise process using a loop reactor, FIG. 5 shows a continuous process for preparing the DMC catalyst dispersion.

In one embodiment of the process according to the invention, the preparation of the double metal cyanide catalyst (DMC) comprises

-   -   i) in a first step, reaction of an aqueous solution of a         cyanide-free metal salt, an aqueous solution of a metal cyanide         salt, an organic complex ligand and a complex-forming component,         to form a dispersion;         -   wherein the reaction is effected using a mixing nozzle;         -   and wherein the temperature of the dispersion during the             reaction is between 26° C. and 49° C.;     -   (ii) optionally, in a second step, the separation of the solid         off from the dispersion obtained from (i);     -   (iii) optionally, in a third step, washing of the isolated solid         with an aqueous solution of an organic complex ligand by means         of a filtercake washing operation;     -   (iv) and optionally, in a fourth step, drying of the solid         obtained.

Step i)

The aqueous solutions of the cyanide-free metal salt, for example zinc chloride, used in stoichiometric excess (at least 50 mol % based on the metal cyanide salt), and of the metal cyanide salt, for example potassium hexacyanocobaltate, are here preferably first reacted in the presence of the organic complex ligand, which may for example be tert-butanol, to form a dispersion. According to the invention, this DMC catalyst dispersion is prepared using a mixing nozzle, preferably a jet disperser.

The preparation of the DMC catalyst dispersion in the semi-batchwise process using a jet disperser in combination with a loop reactor (as per FIG. 4) will be elucidated hereinbelow. In this case, either the aqueous solution of a cyanide-free metal salt can be circulated from the vessel B2 and the aqueous metal cyanide solution can be metered in from vessel B1 or vice versa. When both streams are combined in the mixing element M, a dispersion of the DMC compound is formed. The dispersion of the DMC compound can be prepared by method 1, 2 or 3, preferably by method 2 or 3. The advantage of these methods resides in the possibility of realizing a constant reactant ratio during the entire precipitation process.

Preferably, the dispersion formed after the precipitation is circulated through the jet disperser for an additional few minutes to several hours.

The nozzle diameter is in this case preferably between 2000 μm to 200 μm with pressure drops in the nozzle of between 0.1 bar to 1000 bar.

The organic complex ligand can in this case be present in the aqueous solution of the cyanide-free metal salt and/or of the metal cyanide salt, or it is metered directly into the dispersion obtained after precipitation of the double metal cyanide compound (via vessel B1 or B2).

Preferably, a further complex-forming component is subsequently metered via vessel B1 or B2 into the dispersion circulating through the jet disperser. The complex-forming component is preferably used here in a mixture of water and organic complex ligand.

The metered addition of the complex-forming component into the circuit and a subsequent recirculation preferably takes place under pressure drops in the nozzle of between 0.001 bar and 10 bar.

According to the invention, the DMC catalyst dispersion can also be prepared in a continuous process as is shown by way of example in FIG. 5. The aqueous solutions of the cyanide-free metal salt and of the metal cyanide salt are reacted according to method 1, 2 or 3 in the mixing element M1 to form a dispersion. The organic complex ligand may be present here in the aqueous solution of the cyanide-free metal salt and/or of the metal cyanide salt. In this case, the mixing stage M2 is dispensed with in FIG. 5. It is also possible to add the organic complex ligand after the precipitation of the double metal cyanide compound via the mixing element M2. To increase the residence time of the dispersion, the latter can be circulated via the mixing element M2. The complex-forming component—preferably in a mixture of water and organic complex ligand—can subsequently be added in the mixing element M3 and recirculated to increase the residence time.

Process Temperature

In a preferred embodiment of the process according to the invention, the temperature in step i) is 28° C. to 47° C., preferably 29° C. to 42° C. and particularly preferably 30° C. to 40° C. Here, the process temperature corresponds to the process temperature in vessel B2 in FIG. 4. A process temperature of from 29° C. to 42° C. and of from 30° C. to 40° C. results in a further improvement in the activity of the DMC catalyst.

Step (ii)

In a preferred embodiment of the process according to the invention, in a second step (ii), the solid is separated off from the dispersion obtained from (i).

This involves isolating the solid (that is to say the precursor to the catalyst according to the invention) from the dispersion by known techniques, such as centrifugation or filtration.

Suitable filter apparatuses are described, for example, in “Ullmann's Encyclopedia of Industrial Chemistry”, Vol. B 2, chapters 9 and 10, VCH, Weinheim, 1988 and H. Gasper, D. Oechsle, E. Pongratz (eds.): “Handbuch der industriellen Fest/Flüssig-Filtration” [Handbook of industrial solid-liquid filtration], Wiley-VCH Verlag GmbH, Weinheim, 2000.

The pressure gradient required for the filtration can be applied here by gravitational force, by centrifugal force (e.g. filter centrifuges), preferably by gas differential pressure (e.g. vacuum filter or pressure filter) or by liquid pressure (e.g. filter presses, drum or disk filters and also possibly crossflow filtration modules).

For removal of the catalysts, both batchwise and continuously operated filter apparatuses may be used. Examples of batchwise operating filter apparatuses are peeler centrifuges and inverting filter centrifuges, membrane, chamber, frame or tube filter presses, automatic filter presses, autopress devices, pressure plate, cartridge and plate filters and also vacuum and pressure suction filters. Examples of continuously operating filter apparatuses are belt filter presses, pressure and vacuum drum filters, pressure and vacuum disk filters, belt filters and crossflow filters.

For the filtration of the DMC catalyst dispersion, on the laboratory scale vacuum or pressure filters or vacuum or pressure suction filters are particularly suitable; on the pilot plant and operational scale pressure suction filters, filter presses and automatic filter presses are particularly suitable.

On the pilot plant scale, membrane filter presses have proven to be particularly suitable. These, with the aid of a suitable filter cloth, preferably a membrane cloth, enable the filtration of the DMC catalyst dispersion on the basis of an applied liquid pressure gradient.

The filtration is conducted inter alia at temperatures of from 10 to 80° C. The pressure differences applied may be 0.001 bar to 200 bar, preferably 0.1 bar to 100 bar, particularly preferably 0.1 bar to 25 bar, the pressure difference applied depending on the apparatus used.

Step (iii)

The isolated solid obtained in step (ii) can be washed by means of redispersion or filtercake washing.

In a preferred embodiment of the process according to the invention, in a third step (iii), the isolated solid is washed with an aqueous solution of an organic complex ligand by means of a filtercake washing operation.

The filtercake washing is performed here preferably by slurrying or preferably by flow-through washing. Here, the washing liquid flows through the cake and the liquid previously present in the cake is displaced, with diffusion effects also becoming effective. The removal of moisture from the washed cake can be effected by gas differential pressure, centrifugal force or mechanical pressing, or preferably in a combined manner by removal of moisture by gas differential pressure followed by mechanical pressing out. The pressure for the mechanical pressing out can be applied in this case both mechanically and by membranes.

With the aid of the filtercake washing, the preparation process is simplified and hence also accelerated. The preferred ratio of washing liquid to filtercake volume lies at the amounts which bring about a complete exchange of the amount of liquid present in the original filtercake.

In an alternatively preferred embodiment variant of the process according to the invention, the isolated solid is subsequently washed in a third process step with an aqueous solution of the organic complex ligand (e.g. by redispersion and subsequent reisolation by filtration or centrifugation). This makes it possible to remove, for example, water-soluble by-products such as potassium chloride from the catalyst according to the invention. The amount of the organic complex ligand in the aqueous wash solution is preferably between 40% and 80% by weight, based on the overall solution.

Complex-forming component is optionally added to the aqueous wash solution in the third step, preferably in the range between 0.5% and 5% by weight, based on the overall solution.

It is also advantageous to wash the isolated solid more than once. Preferably, in a first wash step (iii-1) is with an aqueous solution of the organic complex ligand (for example by redispersion and subsequent reisolation by filtration or centrifugation), in order in this way to remove, for example, water-soluble by-products such as potassium chloride from the catalyst according to the invention. Particularly preferably, the amount of the organic complex ligand in the aqueous wash solution is between 40% and 80% by weight, based on the overall solution for the first wash step. In the further wash steps (iii-2), either the first wash step is repeated once or more than once, preferably once to three times, or preferably a nonaqueous solutions, for example a mixture or solution of organic complex ligand and complex-forming component (preferably in the range between 0.5% and 5% by weight, based on the total amount of the wash solution of step (iii-2)), is used as wash solution and the solid is washed with it once or more than once, preferably once to three times.

Step (iv)

In a preferred embodiment of the process according to the invention, in a fourth step (iv), the solid obtained is subsequently dried.

The isolated and possibly washed solid here is subsequently dried at temperatures of in general 20-100° C. and at pressures of in general 0.1 mbar to standard pressure (1013 mbar), optionally after pulverizing.

Steps (ii) and (iii)

In a preferred embodiment of the process according to the invention, steps (ii) and (iii) are performed in a filter press.

It has proven to be advantageous to press out the washed filtercake after the filtercake washing at pressures of from 0.5 to 200 bar, preferably at the highest possible pressures. This can be done, for example, directly following the filtercake washing in a filter press or by means of other suitable pressing apparatuses which enable a mechanical pressure to be applied so that the liquid present in the filtercake can escape through a membrane or a suitable filter cloth. The mechanical removal of moisture from the filtercake, which follows the washing of the filtercake and is preferably to be carried out prior to the drying, can preferably take place in the filter press, preferably by mechanical pressing out via a pressure exerted onto the membranes. The mechanical removal of moisture preferably leads to a maximum removal of the washing liquid from the filtercake.

Steps (ii), (iii) and (iv)

The DMC catalyst is subsequently dried at temperatures of about 20 to 100° C. and at pressures of about 0.1 mbar to standard pressure (1013 mbar). Contact dryers and convection dryers and also spray dryers are suitable for this. The drying is preferably also performed directly in the apparatuses for the mechanical removal of liquid, where these are suitable for this (e.g. suction dryer, centrifugal dryer, “hot filter press”).

In a particularly preferred embodiment of the process according to the invention, steps (ii), (iii) and (iv) are performed in a heatable filter press.

The process preferably employs the heatable filter press. This is constructed as a conventional filter press with a membrane package. In terms of design, the membrane plates to be used differ from conventional membrane plates in that a heating medium can flow through the space behind the membrane. Liquid-tight (so-called “drip-” or “gas-tight”) membrane filter plates are preferably used.

The heated heating medium flows past the filtercakes on the rear side of the press membranes, completely separated from the filtercake by the press membrane and the filter medium, and in the process heats the filtercakes. The pressing medium is in this case under a sufficiently high pressure to ensure contact of the membranes with the filtercakes. The filtercakes can be heated on one or both sides. Heating on both sides is favorable with regard to the drying time.

A vacuum is applied on the filtrate side to assist with the drying process. This vacuum can for example be generated by a liquid-ring pump. The vapor stream suctioned off is cooled upstream of the vacuum pump in order to condense out the volatile constituents (e.g. tert-butanol and water). Measured and controlled variables are the amount condensed out, the pressure in the filtrate system of the press and the filtercake temperature.

In the process described, the membrane pressing pressures are preferably 0.1 bar to 10 bar. Temperatures of the pressing and heating medium are 30° C. to 80° C., preferably 40° C. to 60° C. The filtrate-side pressure is preferably less than 100 mbar. The flow rate of the heating medium should be chosen to be sufficiently high that there is a good heat transfer between the heating medium and the product. Drying times are in general a few minutes to a plurality of hours, typically one to ten hours. Residual moisture contents of below the target value of approx. 5% are reliably achieved with this type of drying.

In further process steps, the product thus isolated and freed from secondary components can be ground and packaged.

Product-by-Process Claim

The present invention further provides the DMC catalyst prepared by the process according to the invention.

The present invention further provides the use of the DMC catalysts prepared by the process according to the invention in a process for preparing polyoxyalkylene polyols, preferably polyether polyols by polyaddition of alkylene oxides onto starter compounds having active hydrogen atoms and/or polyether carbonate polyols by polyaddition of alkylene oxides onto starter compounds having active hydrogen atoms in the presence of carbon dioxide.

The DMC catalysts prepared by the process according to the invention can by virtue of their extraordinarily high activity frequently be used in very low concentrations (25 ppm and less, based on the amount of the polyoxyalkylene polyol to be prepared, preferably the polyether polyol. If the polyoxyalkylene polyols, preferably polyether polyols, prepared in the presence of the DMC catalysts prepared by the process according to the invention are used for the preparation of polyurethanes, removal of the catalyst from the polyoxyalkylene polyol, preferably polyether polyol, can be dispensed with without disadvantageously affecting the product qualities of the polyurethane obtained.

EXAMPLES

OH numbers were determined according to the method of DIN 53240. Viscosities were determined by rotational viscometer (Physica MCR 51, Anton Paar) according to the method of DIN 53018.

Preparation of the DMC Catalysts:

Example 1 (Comparative)

The catalyst was prepared using an apparatus as per FIG. 4 from WO 01/39883 A1.

In a loop reactor containing a jet disperser as per FIG. 2 from WO 01/39883 A1 having one bore (diameter 0.7 mm) was circulated a solution of 258 g of zinc chloride in 937 g of distilled water and 135 g of tert-butanol at 25° C. (determined in the vessel D2 in FIG. 4 of WO 01/39883 A1). To this was metered a solution of 26 g of potassium hexacyanocobaltate in 332 g of distilled water. The pressure drop in the jet disperser was 2.9 bar. Subsequently, the dispersion formed was circulated at 25° C. and a pressure drop in the jet disperser of 2.9 bar for 60 min. Thereafter, a mixture of 5.7 g of tert-butanol, 159 g of distilled water and 27.6 g of polypropylene glycol 1000 (PPG-1000) was metered in and the dispersion was then circulated at 25° C. and a pressure drop in the jet disperser of 2.9 bar for 80 min.

230 g of the dispersion obtained were filtered in a pressure suction filter with filter area 20 cm³, and then washed with a mixture of 82 g of tert-butanol, 42.3 g of distilled water and 1.7 g of polypropylene glycol 1000. The washed filtercake was squeezed mechanically between two strips of filter paper and finally dried at 60° C. under high vacuum at about 0.05 bar (absolute) for 2 h.

Example 2

Example 2 was carried out analogously to example 1 (comparative) with the difference that the DMC dispersion was prepared at 30° C. instead of 25° C.

Example 3

Example 3 was carried out analogously to example 1 (comparative) with the difference that the DMC dispersion was prepared at 35° C. instead of 25° C.

Example 4

Example 4 was carried out analogously to example 1 (comparative) with the difference that the DMC dispersion was prepared at 40° C. instead of 25° C.

Example 5 (Comparative)

Example 5 (comparative) was carried out analogously to example 1 (comparative) with the difference that the DMC dispersion was prepared at 50° C. instead of 25° C.

Example 6 (Comparative)

Example 6 (comparative) was carried out analogously to example 1 (comparative) with the difference that the DMC dispersion was prepared at 70° C. instead of 25° C.

Example 7 (Comparative)

The catalyst was prepared using an apparatus as per FIG. 4 from WO 01/39883 A1.

In a loop reactor containing a jet disperser as per FIG. 2 from WO 01/39883 A1 having one bore (diameter 0.7 mm) was circulated a solution of 258 g of zinc chloride in 937 g of distilled water and 135 g of tert-butanol at 25° C. To this was metered a solution of 26 g of potassium hexacyanocobaltate in 332 g of distilled water. The pressure drop in the jet disperser was 5.0 bar. Subsequently, the dispersion formed was circulated at 25° C. and a pressure drop in the jet disperser of 5.0 bar for 60 min. Thereafter, a mixture of 5.7 g of tert-butanol, 159 g of distilled water and 27.6 g of polypropylene glycol 1000 was metered in and the dispersion was then circulated at 25° C. and a pressure drop in the jet disperser of 5.0 bar for 80 min.

230 g of the dispersion obtained were filtered in a pressure suction filter with filter area 20 cm³, and then washed with a mixture of 82 g of tert-butanol, 42.3 g of distilled water and 1.7 g of polypropylene glycol 1000. The washed filtercake was squeezed mechanically between two strips of filter paper and finally dried at 60° C. under high vacuum at about 0.05 bar (absolute) for 2 h.

Example 8

Example 8 was carried out analogously to example 7 (comparative) with the difference that the DMC dispersion was prepared at 30° C. instead of 25° C.

Example 9

Example 9 was carried out analogously to example 7 (comparative) with the difference that the DMC dispersion was prepared at 35° C. instead of 25° C.

Example 10

Example 10 was carried out analogously to example 7 (comparative) with the difference that the DMC dispersion was prepared at 40° C. instead of 25° C.

Example 11 (Comparative)

Example 11 (comparative) was carried out analogously to example 7 (comparative) with the difference that the DMC dispersion was prepared at 50° C. instead of 25° C.

Example 12 (Comparative)

Example 12 (comparative) was carried out analogously to example 7 (comparative) with the difference that the DMC dispersion was prepared at 70° C. instead of 25° C.

Example 13 (Comparative)

Example 13 (comparative) was carried out analogously to example 3 with the difference that for the preparation of the DMC catalyst the complex-forming component polypropylene glycol 1000 was replaced with cholic acid sodium salt.

Catalyst Test (“8K Diol Stressed Test”):

The DMC catalysts were tested in the so-called “8K diol stressed test”. Here, a polypropylene glycol having a calculated OH number=14 mg KOH/g, that is to say molecular weight=8000 g/mol (“8K diol”) was prepared proceeding from a bifunctional polypropylene glycol starter having an OH number=147 mg KOH/g (“Arcol Polyol 725” from Covestro) with a short propylene oxide metering time (30 minutes). The decisive evaluation criterion for the catalyst quality/activity in this test is the viscosity of the polyol obtained, with a DMC catalyst of increased quality/activity leading to a lower 8K diol viscosity.

General Implementation:

A 1 liter stainless steel reactor was initially charged with 75 g of a bifunctional polypropylene glycol starter (OH number=147 mg KOH/g) and 30.7 mg of DMC catalyst. After changing 5 times between nitrogen and vacuum between 0.1 and 3.0 bar (absolute), the reactor contents were heated to 130° C. with stirring (800 rpm). The mixture was then stripped with nitrogen for 30 min at 130° C. and 100 mbar (absolute). 7.5 g of propylene oxide were then added at 130° C. and 100 mbar (absolute) to activate the catalyst. The catalyst activation manifested in an accelerated pressure drop in the reactor. After the catalyst had been activated, the remaining propylene oxide (685.7 g) was metered in within 30 min at 130° C. with stirring (800 rpm). After a post-reaction time of 30 min at 130° C., volatile constituents were distilled off under reduced pressure (<10 mbar) at 90° C. for 30 min. The product was then cooled down to room temperature and removed from the reactor.

The OH number and viscosity (25° C.) of the product obtained were measured. In the event of a deviation of the measured OH number from the calculated OH number (14 mg KOH/g), a “corrected viscosity” was determined from the measured viscosity using the following formula:

corrected viscosity (25° C.)=measured viscosity (25° C.)+659*(OHN−14)

The results of the catalyst tests in the “8K diol stressed test” are summarized in table 1.

TABLE 1 Pressure OH Viscosity Viscosity Catalyst DMC at the jet Temper- number 25° C./ 25° C./ test/ catalyst/ disp. ature [mg measured corrected Example Example [p] [° C.] KOH/g] [mPas] [mPas] 14  1 2.9 25 13.6 4595 4331 (comp.) (comp.) 15  2 2.9 30 13.8 4125 3993 16  3 2.9 35 13.8 4305 4173 17  4 2.9 40 13.8 4310 4178 18  5 2.9 50 13.8 4525 4393 (comp.) (comp.) 19  6 2.9 70 13.8 5305 5173 (comp.) (comp.) 20  7 5.0 25 13.9 4500 4434 (comp.) (comp.) 21  8 5.0 30 13.9 4190 4124 22  9 5.0 35 13.9 4120 4054 23 10 5.0 40 13.7 4495 4297 24 11 5.0 50 13.7 4610 4412 (comp.) (comp.) 25 12 5.0 70 13.7 5385 5187 (comp.) (comp.) 26 13 2.9 35 13.9 5895 5829 (comp.) (comp.)* *Cholic acid sodium salt instead of polypropylene glycol 1000 as the complex-forming component

The results show that, both with a pressure drop in the jet disperser of 2.9 bar and of 5.0 bar, the lowest viscosity values (corrected) in the “8K diol stressed test” are obtained when the temperature during the preparation of the DMC dispersion is 30-40° C.

In addition, it is apparent that a markedly higher viscosity (corrected) is obtained if the complex-forming component polypropylene glycol 1000 is replaced with cholic acid sodium salt in the preparation of the DMC catalyst. 

1. A process for preparing a double metal cyanide catalyst (DMC) comprising i) reacting an aqueous solution of a cyanide-free metal salt, an aqueous solution of a metal cyanide salt, an organic complex ligand and a complex-forming component, in a first step to form a dispersion; wherein the reaction is effected using a mixing nozzle; and wherein the dispersion during the reaction is at a process temperature of between 26° C. and 49° C.
 2. The process as claimed in claim 1, wherein said mixing nozzle comprises a jet disperser.
 3. The process as claimed in claim 2, wherein said jet disperser has a pressure drop of 0.1 to 100 bar.
 4. The process as claimed in claim 1, wherein said complex-forming component comprises a polyether.
 5. The process as claimed in claim 4, wherein said polyether has a number-average molecular weight of ≥500 g/mol, with the number-average molecular weight being calculated from the OH number.
 6. The process as claimed in claim 5, wherein said polyether comprises a polyether polyol.
 7. The process as claimed in claim 6, wherein said polyether polyol comprises a poly(oxypropylene) polyol having a number-average molecular weight of ≥500 g/mol, with the number-average molecular weight being calculated from the OH number.
 8. The process as claimed in claim 7, wherein said poly(oxypropylene) polyol comprises a poly(oxypropylene) diol and/or a poly(oxypropylene) triol having a number-average molecular weight of 700 g/mol to 4000 g/mol, with number-average molecular weight being calculated from the OH number.
 9. The process as claimed in claim 1, wherein the process temperature in step i) 28° C. to 47° C.
 10. The process as claimed in claim 1, additionally comprising (ii) separating the solid off from the dispersion obtained from (i) in a second step.
 11. The process as claimed in claim 10, additionally comprising (iii) the separated solid from step (ii) with an aqueous solution of an organic complex ligand by means of a filtercake washing operation.
 12. The process as claimed in claim 11, additionally comprising (iv) drying the solid obtained in (iii) in a fourth step.
 13. The process as claimed in claim 11, wherein (ii) and/or (iii) are performed in a filter press.
 14. The process as claimed in 12, wherein steps (ii), (iii) and/or (iv) are performed in a heatable filter press.
 15. A double metal cyanide catalyst (DMC) obtainable by the process in accordance with claim
 1. 16. A process for the preparation of polyoxyalkylene polyols comprising reacting a starter compound with an alkylene oxide in the presence of a double metal cyanide catalyst (DMC) as claimed in claim
 1. 